In some embodiments, a coating applied to steel reinforcement bar (e.g., steel rebar) that could considerably extend the lifetime of concrete structures by reducing steel rebar corrosion is disclosed. The coating includes a thin, passivating steel (e.g., stainless steel) layer that is applied to the outside of conventional steel rebar. The coating can be applied in-line through metal cold spray manufacturing, which is a high throughput coating technique that can be integrated into existing steel manufacturing plants. Furthermore, a novel, high performance ferritic steel with tailored resistance to corrosion from chlorides is described. The new ferritic steel is distinct from other commercial and experimental steels, and is better suited for coating low-cost steel structures like rebar. Multiple alloying elements including Cr, Al, and Si will each form protective oxides independently, increasing the total amount of protection and extending it over much wider ranges of pH and electrical potential.

In some embodiments, a coating applied to steel reinforcement bar (e.g., steel rebar) that could considerably extend the lifetime of concrete structures by reducing steel rebar corrosion is disclosed. The coating includes a thin, passivating steel (e.g., stainless steel) layer that is applied to the outside of conventional steel rebar. The coating can be applied in-line through metal cold spray manufacturing, which is a high throughput coating technique that can be integrated into existing steel manufacturing plants. Furthermore, a novel, high performance ferritic steel with tailored resistance to corrosion from chlorides is described. The new ferritic steel is distinct from other commercial and experimental steels, and is better suited for coating low-cost steel structures like rebar. Multiple alloying elements including Cr, Al, and Si will each form protective oxides independently, increasing the total amount of protection and extending it over much wider ranges of pH and electrical potential.

In some embodiments, a coating applied to steel reinforcement bar (e.g., steel rebar) that could considerably extend the lifetime of concrete structures by reducing steel rebar corrosion is disclosed. The coating includes a thin, passivating steel (e.g., stainless steel) layer that is applied to the outside of conventional steel rebar. The coating can be applied in-line through metal cold spray manufacturing, which is a high throughput coating technique that can be integrated into existing steel manufacturing plants. Furthermore, a novel, high performance ferritic steel with tailored resistance to corrosion from chlorides is described. The new ferritic steel is distinct from other commercial and experimental steels, and is better suited for coating low-cost steel structures like rebar. Multiple alloying elements including Cr, Al, and Si will each form protective oxides independently, increasing the total amount of protection and extending it over much wider ranges of pH and electrical potential.

A method for manufacturing a high-strength steel bar can include the steps of: reheating a steel slab at a temperature ranging from 1000° C. to 1100° C., the steel slab including a certain amount of carbon (C), silicon (Si), manganese (Mn), phosphorus (P), sulfur (S), chromium (Cr), copper (Cu), nickel (Ni), molybdenum (Mo), aluminum (Al), vanadium (V), nitrogen (N), antimony (Sb), tin (Sn), and iron (Fe) and other inevitable impurities, The method can further include finish hot-rolling the reheated steel slab at a temperature of 850° C. to 1000° C., and cooling the hot-rolled steel to a martensite transformation start temperature (Ms (° C.)) through a tempcore process.

A method for manufacturing a high-strength steel bar can include the steps of: reheating a steel slab at a temperature ranging from 1000° C. to 1100° C., the steel slab including a certain amount of carbon (C), silicon (Si), manganese (Mn), phosphorus (P), sulfur (S), chromium (Cr), copper (Cu), nickel (Ni), molybdenum (Mo), aluminum (Al), vanadium (V), nitrogen (N), antimony (Sb), tin (Sn), and iron (Fe) and other inevitable impurities, The method can further include finish hot-rolling the reheated steel slab at a temperature of 850° C. to 1000° C., and cooling the hot-rolled steel to a martensite transformation start temperature (Ms (° C.)) through a tempcore process.

A steel reinforcing bar contains 0.06 wt % to 0.11 wt % carbon, more than 0 and not more than 0.25 wt % silicon, 0.8 wt % or more and less than 2.0 wt % manganese, more than 0 and not more than 0.01 wt % phosphorus, more than 0 and not more than 0.01 wt % sulfur, 0.01 to 0.03 wt % aluminum, 0.50 to 1.00 wt % nickel, 0.027 to 0.125 wt % molybdenum, more than 0 and not more than 0.25 wt % chromium, more than 0 and not more than 0.28 wt % copper, more than 0 and not more than 0.01 wt % nitrogen, and the remainder being iron and unavoidable impurities. The reinforcing bar has a surface layer and a core. The surface layer has a hardened layer of tempered martensite, and the core has a mixed structure of bainite, ferrite and pearlite.

A steel reinforcing bar contains 0.06 wt % to 0.11 wt % carbon, more than 0 and not more than 0.25 wt % silicon, 0.8 wt % or more and less than 2.0 wt % manganese, more than 0 and not more than 0.01 wt % phosphorus, more than 0 and not more than 0.01 wt % sulfur, 0.01 to 0.03 wt % aluminum, 0.50 to 1.00 wt % nickel, 0.027 to 0.125 wt % molybdenum, more than 0 and not more than 0.25 wt % chromium, more than 0 and not more than 0.28 wt % copper, more than 0 and not more than 0.01 wt % nitrogen, and the remainder being iron and unavoidable impurities. The reinforcing bar has a surface layer and a core. The surface layer has a hardened layer of tempered martensite, and the core has a mixed structure of bainite, ferrite and pearlite.

This invention provides a high-strength PC steel wire having a chemical composition containing, in mass %, C: 0.90 to 1.10%, Si: 0.80 to 1.50%, Mn: 0.30 to 0.70%, P: 0.030% or less, S: 0.030% or less, Al: 0.010 to 0.070%, N: 0.0010 to 0.010%, Cr: 0 to 0.50%, V: 0 to 0.10%, B: 0 to 0.005%, Ni: 0 to 1.0%, Cu: 0 to 0.50%, and the balance: Fe and impurities. A ratio between the Vickers hardness (Hv.sub.S) at a location (surface layer) that is 0.1D [D: diameter of steel wire] from the surface of the steel wire and the Vickers hardness (Hv.sub.I) of a region on the inner side relative to the surface layer satisfies the formula [1.10<Hv.sub.S/Hv.sub.I1.15]. An average carbon concentration in a region from the surface to a depth of 10 m (outermost layer region) of the steel wire is 0.8 times or less a carbon concentration of the steel wire. The steel micro-structure in the region on the inner side relative to the outermost layer region contains, in area %, a pearlite structure: 95% or more. The tensile strength of the steel wire is 2000 to 2400 MPa. The method of producing this high-strength PC steel wire is simple, and the high-strength PC steel wire is excellent in delayed fracture resistance characteristics.

This invention provides a high-strength PC steel wire having a chemical composition containing, in mass %, C: 0.90 to 1.10%, Si: 0.80 to 1.50%, Mn: 0.30 to 0.70%, P: 0.030% or less, S: 0.030% or less, Al: 0.010 to 0.070%, N: 0.0010 to 0.010%, Cr: 0 to 0.50%, V: 0 to 0.10%, B: 0 to 0.005%, Ni: 0 to 1.0%, Cu: 0 to 0.50%, and the balance: Fe and impurities. A ratio between the Vickers hardness (Hv.sub.S) at a location (surface layer) that is 0.1D [D: diameter of steel wire] from the surface of the steel wire and the Vickers hardness (Hv.sub.I) of a region on the inner side relative to the surface layer satisfies the formula [1.10<Hv.sub.S/Hv.sub.I1.15]. An average carbon concentration in a region from the surface to a depth of 10 m (outermost layer region) of the steel wire is 0.8 times or less a carbon concentration of the steel wire. The steel micro-structure in the region on the inner side relative to the outermost layer region contains, in area %, a pearlite structure: 95% or more. The tensile strength of the steel wire is 2000 to 2400 MPa. The method of producing this high-strength PC steel wire is simple, and the high-strength PC steel wire is excellent in delayed fracture resistance characteristics.

This invention provides a high-strength PC steel wire having a chemical composition containing, in mass %, C: 0.90 to 1.10%, Si: 0.80 to 1.50%, Mn: 0.30 to 0.70%, P: 0.030% or less, S: 0.030% or less, Al: 0.010 to 0.070%, N: 0.0010 to 0.010%, Cr: 0 to 0.50%, V: 0 to 0.10%, B: 0 to 0.005%, Ni: 0 to 1.0%, Cu: 0 to 0.50%, and the balance: Fe and impurities. A ratio between the Vickers hardness (Hv.sub.S) at a location (surface layer) that is 0.1D [D: diameter of steel wire] from the surface of the steel wire and the Vickers hardness (Hv.sub.I) of a region on the inner side relative to the surface layer satisfies the formula [1.10<Hv.sub.S/Hv.sub.I1.15]. The steel micro-structure in the region from the surface of the steel wire to 0.01D (outermost layer region) consists of, in area %, a pearlite structure: less than 80%, and the balance: a ferrite structure and/or a bainitic structure. The steel micro-structure in the region on the inner side relative to the outermost layer region contains, in area %, a pearlite structure: 95% or more. The tensile strength of the steel wire is 2000 to 2400 MPa. The method of producing this high-strength PC steel wire is simple, and the high-strength PC steel wire is excellent in delayed fracture resistance characteristics.